Sulfur, a common impurity arising from atmospheric and environmental contamination, is highly corrosive and detrimental to the lifespan of nickel superalloys in jet engines. However, sulfur-scavenging coatings have yet to be explored. Our study presents the successful development of a stable, uniform, impurity-scavenging Ni-Mn coating on Ni-based superalloy CMSX-4, through electroplating. The coating was characterised via combined scanning transmission electron microscopy and energy-dispersive X-ray spectroscopy. An optimal coating thickness of > 600 nm was deposited. The coated alloy was exposed to corrosive salt mixture 98% Na2SO4–2% NaCl at 550 °C for 100 h, mimicking engine exposure conditions, thereby proving that the coating successfully trapped sulfur and prevented its diffusion into an underlying alloy. This work presents a promising development for the prevention of sulfur-induced corrosion in industrial setting such as gas turbine engine, where the effects of sulfur diffusion into the bulk alloy could lead to premature failure.
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This article discusses challenges faced in the development of new Ni-based superalloys for applications in the hottest sections of turbine engines and the use of atom probe tomography and correlative microscopy for characterization of these complex alloys with regards to microstructural and compositional design. The two strengthening phases γ and γ′ are introduced and the precipitation of topologically close-packed phases and their potential detrimental effects on superalloy properties are reviewed. Mechanisms of environmental degradation, namely oxidation and hot corrosion, are elucidated and recent research studies on a new phenomenon of hot corrosion at relatively low temperatures below 600°C are discussed. The effect of individual alloying elements on superalloy properties is reviewed, with a focus on Mo and W. The use of atom probe in correlation with state-of-the-art microscopy, spectroscopy and diffraction techniques to study and understand oxidation and corrosion of Ni-based superalloys, including crack tip investigations, is presented.
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Abstract.Here we describe the use of environmentally benign Deep Eutectic Solvents (DESs) to electropolish oxide casting scale from Ni based superalloy turbine blades. These new electrolytes are a viable alternative to hazardous and aggressive aqueous acids and etchants currently used to process these components. In addition we show that the DES electrolytes selectively expose the underlying surface structure of these superalloys. We demonstrate the ability of these electrolytes to preferentially etch either γ or γ phases depending on the choice of electrolyte formulation and the applied potential during the electrolytic etch on CMSX-4 R and CMSX-10 R alloys.
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